KR101889894B1 - Floor underlay - Google Patents

Abstract

A sheet-like product suitable for use as an underlay for a permanently installed floor finish comprising a layer comprising a powder-rubber material and having a first side and a second side. A scrim material is attached to at least one of the first and second surfaces. A high-grip pressure sensitive adhesive coating is applied to at least a portion of the exposed surface of the scrim material. As measured by FINAT Test method No. 2, the adhesive had a delamination adhesive strength of 300 mm / min at a room temperature (23 ° C ± 1 ° C) and a relative humidity of 50% ± 5% A high-grab adhesive with a value in the range of 21.76 Newtons / 25 mm is determined.

Description

FLOOR UNDERLAY

The present invention relates to, for example, underlays for floor corings, and more particularly to powder-rubber underlays.

Powder-rubber underlay, in which the powders are bonded together and at least one side is attached to the scrim layer, has a number of properties that make it particularly useful for high-end products in the marketplace and have been used for floor finishes for over 40 years come. In other words,

● a relatively high mass (density) per unit volume, which makes the material have a high "flop-weight";

● High efficiency sound insulation with high density;

● powder-rubber particles consisting of 80-90% of the volume of the product, consisting of a rubberized rubber and therefore not collapsing over time;

An open-cell structure with the use of synthetic rubber binders to bond the rubber granules together during manufacture of the product;

● During the compression of the product, the granules of the vulcanized rubber are compressed and then immediately returned to the original form when the pressure is released, so that the product is always restored to its original shape and thickness, regardless of the extent or duration of such compression;

Compared to a solid rubber sheet when subjected to a point load, the flexible open cell structure provides a hard, crumpled surface when the product is relatively easily compressed but receives a dispersed load;

• The open-cell structure allows air to flow freely through the product, making the product more "breathable" and more hygienic at the microbial level;

The open-cell structure allows heat transfer through the air circulation but has a relatively good thermal insulation effect;

● After the product is submerged, it dries in place without any performance change or odor; And

• Reinforced grip that most surfaces have on contact as exposed rubber particles form the surface.

Despite these known properties and long-term use, there have been suggestions to provide a pressure sensitive adhesive coating on at least one side of the powder-rubber underlay having a layer of scrim material after 2008. Such an underlay was proposed at ZA 2008/04310 of Rubber Lay (Pty) Ltd. ZA 2008/04310 does not provide special adhesives or properties for such bonding, except that the adhesive is applied directly or applied over the first amorphous coating and may be a hot, hot melt adhesive. An adhesive that is protected by a silicone release paper that can be removed by a floor finish installer to expose the adhesive so that the underside of the floor finish adheres to the exposed adhesive of the underlay is included in ZA 2008/04310.

Rubber Lay (Pty) Ltd liquidated the arbitrage in February 2009 and these underlays were not commercially successful and only very small quantities of their powder-rubber underlay products were produced.

The problem that lies in ZA 2008/04310 lies in the choice of adhesive. This problem, which will be clarified in the detailed description below, has not been sufficiently resolved by any special product of Rubber Lay (Pty) Ltd. The present invention, which may be regarded as a selection from the extensive manual of ZA 2008/04310, provides a solution to the problem. This application claims priority to United Kingdom Patent Application No. 1012089.7 (MJP Deans Reference No: P10749GB) and United Kingdom patent application no. 1012088.9 filed on its behalf, as well as other modified solutions to the problem, And a British patent application (MJP Deans Reference No: P10821 GB) filed by the same can be referred to.

Our analysis of underlay's potential applications, including traditional floor underlay and other applications that follow it, provides two distinct types of underlay: high adhesion (hereinafter referred to as "high-grab " (hereinafter "low-grab") for the best results and for those requiring a high-gravability (" -grab) "

To distinguish between 3 mm or 5 mm flat or 6 mm ribbed products with the distinction between high-grab and low-grab for use in other floor products, Of Table 1 can be referred to.

Type of installation by market segmentation low - grab  product Hi - grab  product 3 mm flat 5 mm flat 6 mm rib 3 mm flat 5 mm flat 6 mm rib Commercial type Carpet (vehicle passage) Woven wide band (double stick) * * Tufted wide band (double stick) * * Tufted tile (double stick, not replaceable) * * Needle punch wide band (double stick) * * Carpet (middle / lower passage) Woven wide rope (single stick) * * * Woven wide carpet (double stick) * * Tufted wide rope (single stick) * * * Tufted wide carpet (double stick) * * Tufted tile (double stick, replacement) * * Tufted tile (double stick, not replaceable) * * Needle punch wide band (single stick) * Needle punch wide band (double stick) * * Needle punch Camet  Tile - Replacement Requirement Needle punch tiles (backed, single stick / double stick) * * Needle punch  Tile - not replaceable Needle punch tiles (unbacked, single / double stick) * * dwelling& DIY  type carpet Woven & tufted wide band (single stick) * * * Tufted tile * * * * Needle punch wide band (single stick) * Needle punch wide band (double stick) * * Needle punch tile (back, single / double stick, replacement) * * Needle punch tile (unbleached, single / double stick) * * Commercial, Residential & DIY  type Wood (all single sticks) Tongue & Groove Solid Floating * * Tongue & Groove Engineer Floating * * Double-click engineer floating * * Laminate * * Vinyl Sheeting (double stick) * Loose lugs (no-slip, removable underlay) *

In accordance with one aspect of the present invention, there is provided a product, generally a sheet-like product, suitable for use as an underlay for a floor finish desired to be permanently installed, the product comprising a powder-rubber material and having a first side and a second side ; A scrim material attached to at least one of the first and second surfaces; And a high-grab pressure sensitive adhesive coating applied to at least a portion of the exposed surface of the scrim material, wherein the high-grab adhesive has a temperature of room temperature (23 DEG C +/- 1 DEG C) and a relative humidity of 50 % ≪ / RTI > ± 5% as measured by FINAT Test method No. 2 and having a value of between 300 mm / min and a 90 degree peel adhesive force of 4.35 to 21.76 Newtons / 25 mm width.

Preferred embodiments can have one or more of the following characteristics: The powder-rubber material comprises an individual rubber powder adhered to each other by a bonding agent. A removable silicone-coated release paper is attached to the exposed adhesive surface.

Embodiments of the underlay according to the present invention are described in more detail below in an exemplary manner with reference to the following drawings.
Figure 1 is a schematic, perspective side view of a portion of a first embodiment of an underlay.
Figure 2 is a schematic side view of a portion of a second embodiment of an underlay.
Figure 3 is a schematic side view of a portion of a third embodiment of an underlay.
FIG. 4 shows a peel adhesion test using FINAT TEST Method No. 2.
FIG. 5 is a graph showing the peel adhesion test results for the adhesive test sample and the comparative sample with different coating weights applied in each case after the 24 hour adhesive binding duration.

Referring to Figure 1, a sheet-like underlay 10 generally comprises a powder-rubber layer 12 having a scrim material 14 attached to one side of the powder-rubber layer. It will be appreciated that the individual powders of the powder-rubber layer need not be uniform in size or oval at the actual cut surface. Powder rubber underlay attached to the scrim is well known and its manufacturing technique, only a brief description is required here. The scrim is attached to the rubber powder, and at the same time the powder is attached to each other. "Wet" powder - a rubber compound (i. E., Including synthetic rubber latex or natural rubber binder) is placed on the scrim before it is moved under a doctor blade passing through to make the wet compound to the correct thickness. The scrim is then passed through a curing oven to transport the wet compound and as a bind set the powder rubber particles are attached to one another and simultaneously pass through a curing stenter oven to transport the compound Respectively. The thickness of the rubber layer is suitably between 2 mm and 15 mm. Although the preferred thicknesses for the various types of bottoms are described in detail in Table 1 above, other thicknesses within the above ranges may also be used. For example, an 8 mm product shows enhanced acoustic performance. The rubber layer may be planarized to have a uniform thickness over the width and length of the underlay as shown in Fig. 1, or may have a corrugated profile on both sides, such as the 6 mm rib version referred to in Table 1 It may be elevated. In the particular embodiment shown in FIG. 1, the high-grab adhesive 16, as defined herein and described in more detail below, is evenly applied to the surface of the scrim material 14. The adhesive may be uniformly applied as a swirl-spray strand or uniform band across the surface of the scrim material 14 or in a dot pattern. Adhesives may additionally be applied to the rubber surface.

The scrim material is a mixture of non-woven polypropylene, woven polypropylene, woven poly-jute, i.e. woven polypropylene and jute, each of which is different in weight, jute, glass fiber Woven glass fiber, woven polyester, woven polyester, nonwoven polyester or stitch bonded crepe paper, it is generally preferred to use 30 g / m 2 or 60 g / m 2 of non-woven polypropylene to be. When actually produced, nonwoven polypropylene having a weight of 60 g / m 2 is preferred.

Although not shown, a film, suitably coated with a silicone release layer as a release sheet, can cover and protect the adhesive and can be peeled off before the underlay is attached to the floor or bottom cover surface by the adhesive 16 .

2 shows a similar underlay 20 in which the powder-rubber layer has a scrim material 24 bonded to both surfaces and also a high-grab adhesive applied to both scrim material layers, 1 in that it has a grab adhesive 26. 3 is similar in that it has a powder-rubber layer 32 having a scrim material 34 bonded to both surfaces, but there is a difference in that the adhesive 36 is applied to only one scrim material layer . Manufacturing the underlay with a double scrim layer is similar to the process described above except that the "wet" rubber powder material is sandwiched between the two scrims and the curing process in the stenter oven proceeds The two scrims are bonded to the embedded material.

The high-grab adhesives 16, 26 and 36 are very important in setting up the type of flooring considered to achieve good results. The underlay of the present invention with a high-grab adhesive is used where the exact location can be easily and accurately found and the flooring installation is permanent and does not require future migration.

A test for peel adhesion was performed on a number of samples using FINAT Test Method No: 2 (described in detail below). The results are shown in Table 2 (below) and Fig.

Different adhesives exhibit different properties, and it is not a suitable indicator to select only the adhesive or only the coating weight; rather, it is possible to consider the adhesive present in the sheet type product suitable for use as a high-grab adhesive In determining whether it can be considered a low-grab adhesive, peel adhesion is the only reliable means. Analyzing the test results described below, even the same adhesive can be a high-grab adhesive or a low-grab adhesive depending on the conditions.

Using the commercial adhesive, Unikem ^TM HPS 800 C, the results shown in Table 2 and FIG. 5 were obtained, but it was equally well available for other commercial adhesives such as Henkel ^TM PD 1573 or Advanced Adhesives ^TM XM 2218 . The experimental data shown in Table 2 and shown graphically in Figure 5 is the average of the values repeated three times for each coating weight of the adhesive. The peel adhesion was evaluated by peel adhesion test conducted after 24 hours of adhesive binding duration at room temperature (23 ° C ± 1 ° C) and 50% ± 5% relative humidity as FINAT Test method No. 2 These temperature and humidity conditions are conditions that are performed in a general experiment. According to FINAT Test method No. 2, which is a test for peel adhesion carried out after the adhesive binding duration has elapsed for 20 minutes, which was carried out in British Patent Application No. 1012088.9, the high- or low- This result is somewhat unreliable, less consistent than the 24 hour duration of adhesive binding, and much shorter for adhesive binding durations, so that for some coating weights, Results. Therefore, FINAT Test method No. 2, which is a peel adhesion test after the 24-hour adhesive binding duration has elapsed, is much preferred as a means of distinguishing whether it is high-grab, low-grab or both do. This generally represents the final peel adhesion of the actual underlay.

For the test, the adhesive coating was carried out with the bulk melter Nordson ^TM MX44160 (Bulk Melter) and Nordson BC31-4 ^TM / 2100 slot nozzle coating head (Slot Nozzle Coating Head) using a Nordson ^TM BM200 drum melter (Drum Melter) . In the drum melter, the heated platen descends to the puddle of hot melt adhesive under the platen by two air cylinders. The hot melt flows into a positive displacement gear pump mounted on the platen and into the bulk melter along the heated hose, and the bulk melter has three main casting assemblies: a hopper, a grid, And a reservoir through which the hot melt passes. The reservoir has four positive displacement pumps, in which the hot melt enters the heated hose through the filter and into the slot nozzle coating head. Pressure transfer and pressure control valves are installed at the outlet of each pump. The slot nozzle coating head has four shutoff valves, a heated hose is connected to the shutoff valve, and the valve controls the flow of adhesive to the slot nozzle. The valve allows the hot melt to enter the inner passageway and the inner passageway has a uniform coating thickness along the width defined by a set of shims. The weight of the coating applied to the substrate, here the scrim lying on the powder-rubber layer, is determined in part by the speed at which the substrate passes through the coating head and the width to which the adhesive is applied.

The weight of the coating applied on the production line can be measured much more easily, but it is more difficult to measure the exact weight of the coating applied to the sample. For different samples, the weight of the coating may be varied by adjusting the rate of movement of the sample through the apparatus. Thus, in order to produce a product in a sheet form suitable for use as an underlay, which generally has high-grab properties, a peel adhesion test that is performed after 24 hours of adhesive bond duration has elapsed within the above- The manufacturing process must be changed (by the speed of movement of the product through the coating device) by adjusting the coating weight until the sample produces a result through FINAT Test method No: 2.

FINAT Test Method No: details of the peel adhesion test according to 2, published by FINAT - is Referring to the "FINAT Technical Handbook Test Methods", 8 th Edition. This test provides an industry standard test for peel adhesion, which involves using a rubber strip for testing, the rubber strip having a width of 25 mm, a length of 200 mm and an adhesive binding duration of 20 minutes or 24 hours , The edge of the rubber strip is pulled vertically from the glass substrate at a rate of 30 mm / min, pulled out from the test rig at an angle of 90 degrees, and the force for this is measured. The contents can be schematically shown in FIG. Various test devices can be obtained from various manufacturers to perform these tests. Tests were conducted on the samples of Table 2 (below) and of Figure 5 using a Cheminstruments ^TM AR-1500 Adhesion Release Tester. Another suitable test device is the JJ Lloyd LR 30K plus Tensometer. This test was performed at room temperature (23 ° C ± 1 ° C) and relative humidity 50% ± 5%, and these temperature and humidity conditions are typical laboratory conditions. The result after 24 hours of adhesive binding duration has elapsed is considered to be a very high value and this value will not improve even after the elapsed time has elapsed. For comparison, the same test was performed using a sample of the original RubberLay ^TM material.

Sample ID After 24 hour adhesive binding duration at room temperature (23 ° C +/- 1 ° C) Newtons / 25 mm Coating weight
(g / m 2) Low Grab Minimum 1.77 One 2.20 10.00 2 3.01 10.40 Low Grab Max 3.96 Hi Grab Minimum 4.35 3 4.40 13.97 4 4.46 14.00 5 4.75 15.84 6 4.89 16.44 7 5.23 23.20 8 5.33 25.20 9 5.68 27.52 10 10.27 64.92 11 10.96 65.20 12 12.09 75.84 13 16.37 89.20 High Grab Max 21.76 Original RubberLay 23.20

Figure 5 illustrates the same result with a "best fit" line through the data points, with a coating weight point with a value of zero added, and a coating weight of zero indicating the value of zero Peel adhesion strength. There are relatively few data points at low coating weights, because it is difficult to add a technically low coating weight. It can be seen that the "best" line does not fit relatively well for some initial data points. In fact, in the case of very low coating weights, no actual bonding takes place. Then, at the critical coating weight, the adhesive appears to be at about 10 g / m ² , and by adding the coating weight before stabilizing the coating with a coating weight of 20 to 30 g / m 2 for slightly less than 6 Newton / 25 mm Peel adhesion increases very rapidly. At much higher coating weights, the rate at which the peel adhesion increases as the coating weight increases increases again.

In areas where the peel adhesion increases rapidly with a coating weight at low coating weight, the peel adhesion has a high-grab property when the adhesive has a low-grab property and the peel adhesion is in the region of a coating weight that stabilizes. This was established by performing tests with coated underlay and samples of different bottom covers.

Sample IDs 1 and 2 were actually detachable from the bottom cover. The carpet tiles could be removed without damaging the underlay. The wood laminate was also easily lifted after installation, so the bottom cover could easily be replaced. These similar characteristics were also found under the rug. The underlay was removed from the lug and replaced. Thus, sample IDs 1 and 2 were of low-grab characteristics.

However, if this same actual installation test was repeated for sample ID 3, when removing the carpet tile, some of the material was removed from the carpet tile and remained in the underlay. When trying to lift a wooden laminate, it was not easily pulled. In some cases, the underlay was damaged when the laminate was removed. Therefore, it is not appropriate to use the sample ID 3 when the bottom cover needs to be replaced. This could not have the properties of a low-grab adhesive, and it has properties as a high-grab adhesive at the bottom of the high-grab region.

Sample IDs 4 to 13 also had high-grab properties.

As a sample, the RubberLay ^TM material has a much higher peel adhesion than any of the test samples. It was very powerful in actual installation tests, did not provide any margin for errors during application, and did not provide a practical approach even in installations that required high-grab characteristics.

Using the above test data, a substantial boundary between the low-grab adhesive and the high-grab adhesive was established with respect to peel adhesion. Sample ID 3 with a peel adhesion of 3.01 Newtons / 25 mm when sample ID 3 with a peel adhesion of 4.40 Newtons / 25 mm is set to have a high-grab property provides a high-grab adhesive The minimum boundary for sample ID 3 was set at 1% below the level of sample ID 3, i.e., 4.35 Newtons / 25 mm, and the maximum peel adhesion for the low-grab property was 10% below the sample ID 3 level 3.96 Newtons / 25mm.

The minimum peel adhesion of 1.77 Newtons / 25 mm for low-grab adhesives is effectively set by the practical problems in the applied adhesive at very low coating weights. We were able to produce a single sample with a coating weight of 3 g / m2 with a peel adhesion of 1.01 Newtons / 25 mm. This single sample was not satisfactory when it was tested in a practical installation requiring low-grab properties, providing insufficient adhesion. The floor finish tended to move after being applied to the underlay. The practical minimum boundary for peel adhesion for satisfactory results can be set by taking an intermediate point between this single unsatisfactory sample and sample ID 1 known to have satisfactory low-grab properties and an additional 10%.

The practical maximum value of peel adhesion for practical high-grab properties can be set from the fact that Sample 13 with a peel adhesion of 16.37 Newtons / 25 mm has satisfactory performance as a high-grap product, while the original RubberLay ^TM material 23.20 Newtons / 25mm peel adhesion, but it was too strong to be used. Thus we can set a practical upper limit for the high-grab peel adhesion by taking the midpoint between these numbers and an additional 10%, and consequently the practical upper limit is 21.76 Newtons / 25mm.

The above values for peel adhesion can determine practical low-grab and high-grab products, regardless of the particular adhesive. Using samples with varying coating weights, for example, a repetition of peel adhesion tests on other adhesives of Henkel ^TM PD 1573 or Advanced Adhesives ^TM XM 2218 gave a similar set of data points with similar optimal curves, but low grab and high grab ≪ / RTI > showed different values from those shown in Table 2 for Unikem ^TM HPS 800 C.

Thus, until the result of the sample is obtained by the FINAT Test method No: 2 peel adhesion test after the 24 hour adhesive binding duration within the high-grav range has elapsed, the above-mentioned or other commonly used pressure In order to produce a generally sheet-like product suitable for use as an underlay having a high-grab property with one selected adhesive, such as a pressure sensitive adhesive, the manufacturing process must be changed by adjusting the coating weight do.

While the above description with respect to Figs. 1 to 3 only concerns the use of a high-grab glue, but also as a double-scrim product, the high- grab glue is applied to one scrim layer, The low-grab adhesive, which is within the range of limits for the other, can be considered to be applied to other scrim layers. In applications of this embodiment, the low-grab glue side is usually applied to the sub-floor while the side of the high-grab adhesive is applied to the bottom cover if the bottom cover should be permanently adhered. Alternatively, with the contrary to the above, it is possible to attach the high-grab glue to the bottom floor and attach the low-grab glue to the bottom cover, since each carpet tile must be dirty and moved to another place or replaced This is useful if you need to replace the floor cover often, as it should.

Alternatively, there may be a high-grab glue on the scrim layers on either side of the powder rubber layer, or a high-grab glue on one of the scrim layers and a high-grab glue or low- Can be attached directly to the material.

Claims (7)

A sheet-like product suitable for use as an underlay for a permanently installed floor finish,
A layer comprising a powder-rubber material and having a first side and a second side;
A scrim material attached to at least one of the first and second surfaces; And
A high-grip pressure sensitive adhesive coating applied to at least a portion of the exposed surface of the scrim material;
, And the high-grab adhesive was measured by FINAT Test method No. 2 at a room temperature (23 ° C ± 1 ° C) and a relative humidity of 50% ± 5% for 24 hours after the adhesive binding duration of 300 mm / Wherein the peel adhesion is an adhesive having a value in the range of 4.35 to 21.76 Newtons / 25 mm.
The method according to claim 1,
Wherein the powder-rubber material comprises individual rubber powders adhered to each other by a bonding material.
The method according to claim 1,
Characterized in that a layer of scrim material is attached to both said first and second sides and said high-grab adhesive is applied to at least a part of the exposed surface of said scrim material on both sides of said product. product.
The method according to claim 1,
Wherein a scrim material layer is attached to both the first and second sides and wherein the high graft adhesive is applied to at least a portion of the exposed surface of the scrim material on the first side, Is applied to at least a portion of the exposed surface of the scrim material on the second side,
The low-grab adhesive was measured by FINAT Test method No: 2, and after 24 hours of adhesive bonding at a room temperature (23 ° C ± 1 ° C) and a relative humidity of 50% ± 5% Wherein the adhesive is an adhesive having a value in the range of 1.77 to 3.96 Newtons / 25 mm.
The method according to claim 1,
Wherein a release paper is attached to said exposed adhesive surface or each exposed adhesive surface.
A layer comprising a powder-rubber material and having a first side and a second side, a scrim material adhered to at least one of the first and second sides, and a pressure sensitive material applied to at least a portion of the exposed surface of the scrim material A test method for determining if a sheet product comprising an adhesive coating is suitable for use as an underlay for a permanently installed floor finish,
Performing a 300 mm / min 90 degree peel adhesion test after a 24 hour adhesive binding duration at room temperature (23 DEG C +/- 1 DEG C) and relative humidity of 50% +/- 5% as measured by FINAT Test method No: 2; And
Judging that a 90 ° peel adhesion force is appropriate if it is between 4.35 and 21.76 Newtons / 25 mm;
≪ / RTI >
CLAIMS 1. A method of making a sheet-like product suitable for use as an underlay for a permanently installed floor finish,
Attaching the rubber powders to each other to form a powder-rubber layer and to support the scrim material on at least one side of the formed powder-rubber layer; And
Applying a pressure sensitive adhesive to at least a portion of the exposed surface of the scrim material such that the adhesive has been measured by FINAT Test method No. 2 for 24 hours at room temperature (23 ° C ± 1 ° C) and relative humidity 50% ± 5% Making the 300 mm / min 90 degree peel adhesion force to be in the range of 4.35 to 21.76 Newtons / 25 mm after the adhesive binding duration;
≪ / RTI >

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